Manufacture of pile fabrics



April '30, 1935. w. MICHAELls `1,999,883

MA-NUFACTURE OF PILE FABRICS April 30, 1935.

` W. MICHAELIS MANUFACTURE oF PILE FABRICS Filed March 50, 1931 4Sheets-Sheet 2 April 30, 1935. W MlcHAELlS 1,999,883

MANUFACTURE OF PILE FABRICS Filed March so, 1951 4 Sheefsshee1 5 April30, 1935 I w. MICHAl-:Lls 1,999,883

I MANUFACTURE OF PILE FABRICS Filed March-3o, 1931 4 sweets-sheet 4Patented l Apr. 30, 1935 l. gUNITED vSTAT MANUFACTURE vor l.PILEFABRICS, i'

Wolfgang Asplgation March l3o, 1931,

Michaelis, Neubabelsberg, near Potsdam, Germany yserial No.152a374 InGermany May I0, 1930 v 8 Claims. '(Cl. 139-405) This invention relatesto wire warp pile fabrics withback patternV woven through, inparticularfor the production of carpets and the like, which are very similar inappearance to real Oriental carpets. With the fabric, to which theinvention refers, there are present in the fabricnot only the pile warpthreads formingthe pattern at the moment but also the other pile warpslie assocalled dead pile warps between the upper and the backing weft.in the fabric. e ,Y

With one known wire warp pile fabric of the kind mentioned, the pilewarp threads forming the pattern are simply tied underneath thebase warpby backing wefts.. rThe disadvantage of the said method of weavingconsists, onthe one hand, in the comparatively easy loosening of thepile threads from the fabric, and on the othery hand, the back of thefabric, in spite of the` back pattern woven through, has-not theappearance of the back of real Oriental carpetsas the'cross entanglementof the pile warp threads forming the pattern is wanting y n l, Withanotherknown kprocess,by theV aidof which wire warp pile fabrics withback patterns woven through and dead pile warps lying in the fabric areproduced, a twisting of theA pile warp threads round `the ground warptakes place, -It is characteristic, however, of the last-mentionedprocess that all the pile warp threads, -that is therefore both the onesserving lat the moment to form the pattern as well as the deadpile warpthreads, lie permanently twisted in the weaving process. The treatmentof the pile warp thread serving to form the pattern differs from thetreatment of the other pile warp threads simplyl in that the pile'warpthread servingto formthe patternis lifted up, in order to place itover the wire. With this known process, the permanent twisting ofall thepile warp threads has the great disadvantage that the pile Warp threadsare heavily stressed. In carrying out the last-mentioned process,therefore, either material of great strength and consequentlyL*expensive, is necessary for the pile warp threads, or the pile warpthreads must` consist of highly twisted material which has thedisadvantage of forming an uneven pile. Furthermore, a considerablyincreased consumptionV of material is connectedwith the process inquestion, which is to be attributed to the Working in of the permanentlytwisted dead pile warp threads. Finally,

owingto thepermanent twisting of all the pile warpthreads, the faultstaking place in weaving, in particular the formation of' knots, areincreased.; I

' By means ofthe process according to the present invention`thedisadvantages attaching to the Aknown processes are avoided. The processaccordingtotheinvention is characterized by a lesser1V 'consumption ofvmaterialand arsmaller 5 stressingoffthe pile warpl threads, and producesa strong close fabric with good pile formation in which the pile threadsareffsormly tied inv that theycannot practically be detached from thefabric; According to the invention, of the pile warp threadslying'untwisted in the fabric, the pile warpA threads lifted at themoment to make the pattern,` are carried to the back of the'fabric andthere interlaced round the ground warp in half twistweave. .Y f

4'Owing to the fact that only the pile warp threads lifted up over thewires are twisted,while the ,other` dead pilev warp threads lieuntwi'sted in the fabric,-the pile Warp Vmaterial is greatly protected.Furthermore, with the process according to the invention,v less stronglytwisted yarns which permit of a closer -pile can be used. There is alsoa considerablen saving of material attaching'A to the process accordingto the` invention,l as Vthe dead pile warp threads lie in thefabricwithout working in. The saving in material can. also be increasedwiththe process according to the in- Vention by the firmer interlacing whichis made possible by the twisting of only the pile warp threads formingthe pattern. Furthermore, the interlacing takes placepreferably alwaysonly round one ground warp thread, which also effects afsavin'glof'ina'terial.` As, furthermore, only the pilerwarpthreads serving toform the. pattern are carried to the back of the fabric, the possi#bility of the occurrence of faults in weaving in consequence of knotsand the like, is reduced. Finally,4 a considerable saving in power andtime is effected in the process according to the invention. Y A 40 Theinvention is more fully explained on the drawings by means of a numberof examples of carrying it out. Y v n Y Figs. 1 and 2 showa double weftwire warp pile fabric according tothe invention;diagrarnmati-v 'A callyin longitudinal section and in plan.- Fig. 3 also shows a double weftwire warp pile fabric according to the invention with altered positionof the top weft, diagrammatically in tudinal section and in plan atriple' weft' wire Warp pile fabric according tothe invention, whileFigs. 6 andY 'Zalso show a triple weft wire warp 55 and in plan a fabriccorresponding to that shown in Figs. 1 and 2 in which thewire is placedAin the knot and the lower weft introduced into the loop.

Figs. 12 and 13 are similar views of -afabric corresponding to thatshown in Figs. 4 and 5 modied in the same manner as Figs. 1'0 and 11.

Figs. 14 and 15 are similar views `of a'fabric' corresponding to thatshown in Figs.; .6, and '7;

In the figures', I indicates ltheground warp. 2, 3, 4,5, v( are fivepile'warps which serve to form the pattern, and which consequently havethe different colours necessary for theformation of thepattern.'I'in'dicates the binding warp. The fabricsshownin Figs. 11' to 3 "aredouble weft fabrics, 8 indicating the top weft, and 9 the lower weft,which are introduced with each working cycle. I0 indicatesthe wires overwhich the pile warp threads lifted up at any time in order to form thepattern, are laid'. i

`The process for A,the production of the fabric according to Figs. land2 takes place in much the 'The weft 8 isintroducedv underrthe bindingwarp, while the ground warp and all the pile warps are lowered.Atthefs'ame'time, 'or 1mmediately afterwards, thatthread 'of the pilewarp, as for example the thread I5` `which isl to serve to form thelpattern, is lowered by means of the jacquard mechanism under the otherpile warp threads 2, 3, 4, 5 and under the ground warp I. The same thingcan be attained by the pile warp threads 2,'3, 4 and 5, and thegroundwarp I being raised.'y The pile warp thread serving to form the patternis drawn away under the ground-warp, Vand is 'brought twisted into theupper shed, so that the parta (see Fig. 2) is formed.' t' j i After theraising of the pile threadstwisted at the side, a second'weft 'threadSfis 'introduced over the ground and binding warp," and under the partlytwistedfandpartly"untwisted pile warp threads. The members which haveeffected the raising of the pile warpthread twisted round the groundvwarp then sink, `so that this pile warp thread springs back; Finally,the previously twisted pile warp thread is lifted up by means ofjacquard cords into a straightl direction (see part b) in order to beplacedin the upper shed over the wire I0. In the bottom shed, on theother hand, are the ground and binding warps, as also the socalled deadpile warp threads which do'not take part in the formation of thepattern.

After the pile warp thread raised over the wire has been lowered, rstthe binding warp is again raised alone in to the upper shed, and a freshweft 8 is inserted. The Vtwisting of the next pattern forming pile warpthread then begins, this lying, after its lifting, twisted in the uppershed, whereuponv the. lower weft V9 fis inserted; The pattern formingthreadspringsA back andv is finally laid over the wire.v this manner,the'working Vcycleis continuously'repeated.

= In order to carry out the above described'proca double-repeatweaving'loom. Apart from the introduction of the upper weftsimultaneously Y` with the fwire; the process for making the fabricaccording to Fig.;3'is'entirely the same as the above described process.y

The fabric whichkis shown in Figs. 4 and 5 differs from vthefabricaccording to Figs. 1 and 2 bythe fact'that between the pile warp threadserving to form the pattern, after it is lowered below the ground warpI, and the ground warp, a third weft Il is introduced, by means offwhichthe principal purpose in View' is to bring theback pattern of the carpetfully into accord with the back pattern of real Orientalcarpets. Withthe object of- Figs.- 4 and 5, the binding'warp 'I is also wovenbelowthe ground warp I by the weft thread II. TheA binding warp 'I does not,however, need to be woven'underneath the -ground warp, but can be alsointerlaced in the manner shown from Figs. 1 and 3 by the lower weft 9,which`lies above the ground warp I`. Y

Apart from the introduction ofthe second lower` weft II the process forthe production ofthe fabric according to Figs. 4 and 5 ispthe same asthat above described for the Figs. 1 and 2. Y I

In Figs.' 6 Yand 7 a triple weft fabric is also shown and there are alsoAhere two bottom wefts. The one bottom weft 9 has the sameposition andthe same function'as the bottom weft 9 according to Figs. 1 and 2, whilethe second bottomV weft I2, after the introduction of the weft thread Sis introduced above the ground warp and the pile Y warp Vthread servingto form the pattern, and underneath the vbindingwarp andthe dead pilewarp threads. -The weftthread I2 has'the object of making the fabricstill thicker. Apart from the introduction of the'weft thread I2, theprocess'of production is the same with the object of Figs. 6 to7,-aswith the object of Figs. 1 and 2. In theV production of the tripleweft fabrics according to Figs. 4 to 7, four-'repeat looms are to beused. With the Afabrics according toY Figs. 4 to 7, the upper weft 8can, in the same way as has been explained in the case of Fig 3, beintroduced simultaneously with the wire ,I0 (Figs. 8 and 9). In thiscase, only three repeat looms are necessary for the production of thefabric according to Figs. 4 to 7.

In order to obtain a similarity to real Persian carpets'i'n'the matterof the fringe making, the 4ground warp I may be allowed to project fromthe woven goods so that it can be used for the knotting of the fringe. j

The wire. can also be placed in the knot a (see Figs. 2, 5 and'l)4 andin place of this the lower weft 9 be introduced above the ground warp inthe part b (Figs. `10 to 15).

Iclaim: l

V1. A wire warp pile fabric having a'plurality of ground warp threads,each of said ground warp threads having associated therewith a pluralityof pile warp threads, and weft threads, saidA pile warp threads servingto form patterns, each of said pile Warp threads having'atselectedloca'- tions a portion extending above the faceof the fabric toform the pattern and an adjacent portion bent around the ground warpthread with which said pile warp thread is associated and forming a loopon the opposite side of said ground warp thread from said patternforming portion, and a weft extending through said loop, the portions ofthe other pile warp threads associated with such ground warp threadadjacent said pattern forming portion and bent portion lying unbent inthe fabric.

2. A wire warp pile fabric having a plurality of ground warp threads,each of said ground warp threads having associated therewith a pluralityof pile warp threads,A and weft threads, said pile warp threads servingto form patterns, each of said pile warp threads having at selectedlocations a portion extending above the'face of the fabric forming aloop and an adjacent portion bent around the ground warp thread withwhich said pile warp thread is associated and engaging the lower sidethereof and forming a loop on the opposite side of said ground warpthread from said pattern forming portion, and a weft thread extendingthrough said second loop, the portions of the other pile warp threadsassociated with such ground warp thread adjacent said loop and bentportion lying unbent in the fabric, said first loop being on the sameside of the ground warp thread as said unbent portions.

3. A wire warp pile fabric having a plurality of ground warp threads,each of said Aground warp threads having associated therewith, aplurality of pile warp threads, and weft threads, said pile warp threadsserving to form patterns, each of said pile warp threads having atselected locations a portion extending above the face of the fabric toform the pattern and an adjacent portion bent around the ground warpthread with which said pile warp thread is associated and engaging thelower side thereof and forming a loop on the opposite side of saidground warp thread from said pattern forming portion, the portions or"the other pile warp threads associatedwith such ground warp threadadjacent said pattern forming portion and bent portion lying unbent inthe fabric, said weft threads comprising an upper weft thread and a,lower weft thread located between said ground warpvthread and said pilewarp threads, said lower weft thread extending through said second loop.

4. A wire warp pile fabric having a plurality of ground warp threads,each of v.said ground warp threads having associated therewith aplurality of pile warp threads, and weft threads, said pile warp threadsserving to form patterns each of said pile Warp threads having atselected locations a portion extending above the face of the fabric toform the pattern and an adjacent portion bent around the ground warpthread with which said pile warp thread is associated and engaging thelower side thereof and forming a loop on the opposite side of saidground warp thread from said pattern forming portion,

the portions of the other pile warp threads associated with such groundwarp thread adjacent said pattern forming portion and bent portion lyingunbent in the fabric, said weft threads comprising an upper weft thread,an intermediate weft thread between said ground warp thread and saidpile warp threads and extending through said loop, and a lower weftthread lying Vbelow the ground warp thread, said bent portion of saidpattern forming warp thread engaging said lower weft thread and bindingthe same against said ground warp thread.

5. The process for producing wire warp pile.

fabrics having ground warp threads, a plurality of pile warp threadsassociated with each ground warp thread, and weft threads, whichcomprises carrying that one of the pile warp threads which formsv thepattern at any point to the back of the fabric and bending the samearound the ground warp thread, while leaving the adjacent portions ofthe remaining pile warp threads unbent in the fabric, formingy a'loop inan adjacent portion of said pattern forming thread on the opposite sideof the ground warp thread from the pattern forming'fportion, inserting aweft thread through said loop, and repeating said steps for each of saidpile warp threads selectively to form a pattern. Y l

6. In a process as claimed. in claim 5the step of inserting a weftthread below said ground warp thread and between said ground warp threadand that portion of the pattern forming pile warp thread which is bent`around the ground warp thread. Y

7. In a process as claimed in claim 5, the step of inserting a weftthread between Vsaid pile warp threads and said ground warp thread at apoint outside the said loop.

8. A wire warp pile fabric having a plurality of ground warp threads,each of .said ground warp threads having associated therewith aplurality of pile warp threads, and weft threads, said pile warp threadsserving to form patterns'each of said pile warp threads having atselected locations a portion extending above the face of the fabric toform the pattern and an adjacent portion bent around the ground warpthread with which said pile warp thread is associated and engaging thelower side thereof and forming a loop on the opposite side of saidground warp thread from said pattern forming portion, the portions ofthe other pile warp threads associated with such ground warp threadadjacenty WOLFGANG MICHAELIS.

